PIONEER PUMP - Microsoft

PIONEER PUMP VACUUM ASSIST SYSTEM (CONT.) Exhaust Valve (Closed) Actuator Valve (Open) Inlet Valve (Closed) 12 O'CLOCK 3 O'CLOCK With the pump drive pulley operating from the 12 o’clock position, the piston rod and crank force the piston in a downward direction. Increasing air pressure below the piston closes the inlet valve and opens the actuator valve. Air is allowed to flow into the upper chamber of the pump casing (above the piston) until the drive pulley reaches the 6 o’clock position. Exhaust Valve (Open) Actuator Valve (Closed) Inlet Valve (Open) 6 O'CLOCK 9 O'CLOCK From the six o’clock position, the piston rod and crank force the piston in an upward direction. Increasing air pressure above the piston opens the exhaust valve and forces the actuator valve closed. Air is then pushed out of the area above the piston and through the exhaust valve until the drive pulley again reaches the 12 o’clock position. At the same time, as the piston is pushed upward, a vacuum is created in the lower chamber of the pump casing (below the piston). The vacuum pulls the inlet valve open, and air flows into the pump past the inlet valve. This cycle repeats itself until the inlet of the pump is closed either by the valves in the priming chamber or by closing the ball valve on top of the priming chamber. In the “closed” condition, no air enters the vacuum pump. The inlet valve, the piston valve, and the exhaust valve all remain closed. Without air entering the pump, minimal vacuum is created below the piston on its upstroke, so the inlet valve remains closed. Air flow is stopped through the pump. The pump can idle in this manner indefinitely or until a demand is made on it to again evacuate the system. 8

PIONEER PUMP VACUUM ASSIST SYSTEM (CONT.) Pioneer Prime Only The vacuum pump is either top-mounted or side-mounted on Pioneer Prime (PP) series pumps. The pump can be serviced in either configuration, whether mounted to the centrifugal pump or removed. Removing the Vacuum Pump Drive System The vacuum pump drive system consists of a drive pulley on the main pump drive shaft, a rubber drive belt, and a drive pulley attached to the vacuum pump drive shaft. If the vacuum pump is top-mounted, remove the retaining cap screws and remove the adjusting shims to release drive belt tension. If the vacuum pump is side-mounted, loosen the drive belt adjuster to release drive belt tension. To remove the pulley on the centrifugal pump drive shaft, first remove the centrifugal pump from the driver, then remove the drive coupling. The drive removal procedure is covered in the “SAE Housing and Coupler” section of this manual. With the drive coupling removed, the vacuum pump drive pulley can be accessed. 1. Before removing the pulley, measure and record the distance between the face of the pulley to the end of the shaft. This measurement will be required to position the pulley when reinstalling it. 2. Remove two set screws in the pulley root. 3. Remove 1/2" bolt from the two-piece wedged key. 4. Use a 3/8" threaded bolt to drive the two parts of the two-piece wedged key apart. 5. Once the key is apart, one half of the key can be removed, and the pulley can be removed from the shaft. Once the pulley is removed, the remaining part of the key can be removed from the shaft. 9

PIONEER PUMP VACUUM ASSIST SYSTEM (CONT.) Disassembly Vacuum pump disassembly is done in two sections. The first part is the upper section, followed by the lower section. Vacuum Pump Upper Section Exhaust Valve Disassembly To remove the exhaust valve, remove the cap screws securing the exhaust nozzle to the upper housing, and lift the housing off. The exhaust valve is now exposed. It is not necessary to remove the valve stud when removing the exhaust valve—simply pull the exhaust valve off over the head of the valve stud. Inlet Valve Disassembly To remove the inlet valve, remove the cap screws securing the inlet nozzle to the lower housing. The inlet valve is now exposed. It is not necessary to remove the valve stud when replacing the inlet valve—simply pull the inlet valve off over the head of the valve stud. Actuator Valve and Actuator Seal Disassembly To check or replace the actuator seal, actuator valve, or neck seal, remove the upper housing bolts, nuts, and washers, and lift the upper housing off. The actuator valve is now exposed. To remove the actuator valve, remove the cotter pin and castle nut at the center of the valve. The actuator valve can now be removed by simply pulling it off over the head of the valve stud. To remove the actuator seal, remove the cotter pin and castle nut securing the actuator to the actuator shaft. Rotate the crankshaft so the actuator moves to “top dead center” position. Work the actuator seal out of the groove in the lower housing. The actuator has two threaded holes on the top to enable attachment of a puller for removal of the actuator. The threads in the actuator are 3/8"-16 UNC. If a suitable puller cannot be found, Pioneer Pump, Inc. can supply a puller or puller drawing (on request). The actuator seal will be normally be replaced once it has been removed. The easiest way to remove the actuator seal is to clamp the actuator in a vice, cut the actuator seal with a utility knife, and pull the actuator seal out of the groove. 10

PIONEER PUMP VACUUM ASSIST SYSTEM (CONT.) Vacuum Pump Lower Section Lower Housing and Neck Seal Disassembly 1. With the actuator removed, remove the nuts and washers from the studs securing the lower housing to the pedestal. Apply a lubricant, such as petroleum jelly, to the exposed portion of the actuator shaft. 2. Lift the lower housing off the pedestal. The neck seal will remain with the lower housing. 3. Remove the neck seal from the counterbore in the bottom of the lower housing. 4. To further disassemble, remove the cap screws securing the pedestal to the crankcase and lift the pedestal off over the actuator shaft. Take care to support the actuator shaft so that it doesn’t become marred or damaged by contact with the crankcase. 5. Rotate the crankshaft to bring the actuator shaft to its top dead center position. 6. Remove one of the retaining rings at one end of the fulcrum pin. Remove the fulcrum pin, the connecting rod small-end bearings, and the actuator shaft bearing. Slide the connecting rod as far to one side of the crankshaft as possible. With a pair of pliers, remove the oil flinger from the crankshaft. 7. Remove the bearing cap fasteners from both the drive end and the opposite drive end, then remove the shaft-end bearing cap and opposite shaft-end bearing cap. Push the crankshaft far enough out the opposite drive end to access the bearing locknut. Remove the bearing locknut and bearing washer. 8. The crankshaft can now be pulled out of the drive end of the crankcase. The opposite drive end crankshaft roller bearing should remain in the crankcase. The drive end crankshaft roller bearing may slide off the crankshaft by hand or may have to be removed with a gear puller. 11

PIONEER PUMP VACUUM ASSIST SYSTEM (CONT.) Lower Housing and Neck Seal Disassembly (Cont.) 9. The connecting rod can now be lifted out of the top of the crankcase. Inspect the connecting rod small-end bearings for uneven or excessive wear. If the inside diameter of the installed connecting rod small-end bearings exceeds 0.628" (15.95 mm), the bearings should be replaced. NOTE! If the connecting rod is to be replaced, the new parts will be complete with new bearings. No further machining or reaming will be required. If only the bearings will be replaced, remove the old bearings. To remove the old bearings, press them out using a suitable mandrel. To install the new bearings, press them in using a suitable mandrel. After the new connecting rod small-end bearings are pressed in, ream them to an inside diameter of 0.6255" (15.88 mm) to 0.6260" (15.90 mm). 10. The actuator shaft bearing should be inspected for uneven or excessive wear. If the inside diameter of the installed actuator shaft bearing exceeds 0.628" (15.95 mm), the bearing should be replaced. To remove the old bearing, press it out using a suitable mandrel. To install the new bearing, press it in using a suitable mandrel. After the new actuator shaft bearing has been pressed in, ream it to an inside diameter of 0.6255" (15.88 mm) to 0.6260" (15.90 mm). 11. Inspect the connecting rod large-end bearing for excessive or uneven wear. If the inside diameter exceeds 2.007" (50.98 mm), the bearing should be replaced. To remove the old bearing, press it out using a suitable mandrel. To install the new bearing, press it in using a suitable mandrel. Be sure to install the connecting rod large-end bearing with the joint in the bearing aligning to the right or left side of the bore in the connecting rod, not at the top or bottom. This bearing requires no finishing after machining. 12. If the drive end bearing cap lip seal is to be replaced, it should be pressed into the counterbore on the inside of the bearing cap with the lip pointing toward the crankcase. 13. Check the actuator shaft guide bearing for excessive or uneven wear. If the inside diameter of the installed actuator shaft bearing exceeds 1.385" (35.18 mm), it should be replaced. It will be necessary to remove the actuator shaft lip seal from the pedestal in order to remove and reinstall the actuator shaft guide bearing. 14. A new actuator shaft lip seal should be installed after the new actuator shaft guide bearing is installed and reamed as needed. The actuator shaft lip seal is to be installed with the lip pointing downward. After installation, the inside diameter of the actuator shaft guide bearing should be wiped with a thin layer of grease. Vacuum Pump Bearing Cap Showing Correct Seal Orientation 12 Bearing Cap Lip Pointing Toward Bearing Housing

PIONEER PUMP VACUUM ASSIST SYSTEM (CONT.) Reassembly 1. Install the shaft-end ball bearing on the crankshaft. If it does not slide on by hand, heat it uniformly in an oven or on a hot plate to approximately 200 F (95 C), then quickly slide it onto the shaft securely up against the shaft shoulder. WARNING Use proper protective gloves and clothing when handling heated parts! 2. Hold the connecting rod in the crankcase. Slide the crankshaft assembly through the drive end opening of the crankcase through the connecting rod large-end bearing. 3. Now slide the opposite drive end bearing onto the crankshaft through the crankcase bore. If it does not slide on by hand, heat it uniformly in an oven or on a hot plate to approximately 200 F (95 C), then quickly slide it onto the shaft securely up against the shaft shoulder. WARNING Use proper protective gloves and clothing when handling heated parts! 4. With the tabs pointing away from the bearing, install the bearing washer at the opposite drive end bearing. Make certain that the tab on the inside diameter of the bearing washer engages with the slot on the shaft. 5. Install the bearing locknut with the beveled side toward the bearing. Tighten the bearing locknut to a firm torque. Further tighten the bearing nut until one of the tabs lines up with a slot on the bearing nut. Bend one of the tabs on the outside diameter of the bearing washer down into one of the slots on the outside diameter of the bearing locknut. 6. Reinstall the opposite drive end bearing cap. Make certain that the bearing cap O-ring is mounted on the bearing cap. Bearing Nut Align a tab on the bearing washer with a slot on the bearing nut, then bend the tab into the slot. Bearing Washer 7. Reinstall the oil flinger in the crankshaft. 8. Assemble the connecting rod to the actuator shaft by sliding the fulcrum pin through the bores in the connecting rod and the actuator shaft. Install the fulcrum pin retaining rings on the fulcrum pin. 9. Reinstall the pedestal to the crankcase, being sure that the pedestal O-ring is in place. Using the torque chart in the appendix, torque the cap screws attaching the pedestal to the crankcase. 10. Lubricate the inside diameter of the neck seal and push the neck seal over the end of the actuator shaft. 13

PIONEER PUMP VACUUM ASSIST SYSTEM (CONT.) Actuator Seal Installation NOTE: The actuator seal is directional. It must be installed with the correct side up on the actuator. Actuator Seal Orientation With the actuator clamped in a vice, thoroughly lubricate the inside diameter of the actuator seal and the groove in the actuator. It is easiest to work the seal onto the actuator by working in four sectors. This will help avoid bunching of the seal in one location. Starting at the 12 o’clock position and using a blunt tool (such as a wrench handle), work a small section of the seal into the groove. Then do the same at the 3 o’clock, 6 o’clock, and 9 o’clock positions. Work your way around the actuator, working the seal into the groove until it is installed. Installing the Actuator on the Actuator Shaft The actuator must be heated before installation onto the actuator shaft to provide a correct fit. The actuator will be hot, so use gloves or other appropriate clothing to protect yourself while handling heated materials. With the actuator clamped in a vice, follow the diagram below for the heating procedure. 1. Apply heat directly to bore for 30 to 40 seconds. 2. Apply heat to top of actuator for 15 to 20 seconds. 3. Apply heat to bore again for 15 to 20 seconds. With the actuator heated, install it to the actuator shaft. Apply Loctite 262 or equivalent thread-locking fluid to the threads of the actuator shaft. Install the castle nut. Tighten the castle nut to 25 ft-lbs (34 Nm). While tightening, make certain to align one of the slots in the castle nut with the cotter pin hole through the actuator threads. Install the cotter pin. 14

PIONEER PUMP VACUUM ASSIST SYSTEM (CONT.) Inlet Valve Assembly When installing a new exhaust valve, lubricate the head of the valve stud and push the exhaust valve on over the head of the valve stud. When reattaching the inlet nozzle/valve carrier, check the condition of the inlet nozzle/valve carrier gasket and replace as necessary. Actuator Valve Assembly When installing a new actuator valve, lubricate the head of the valve stud and push the actuator valve over the head of the valve stud. Apply thread-locking fluid (Loctite or similar) to the threads. Reinstall the castle nut, tightening the nut to 25 ft-lbs (34 Nm). Reinstall the cotter pin. Upper Housing Assembly Install the upper housing. There are two versions of the upper housing: Earlier versions used a blind hole arrangement for securing the aluminum upper housing to the aluminum lower housing. In this case, tighten the cap screws using the aluminum torque chart in the appendix. DO NOT OVERTIGHTEN the cap screws or the threads in the aluminum housing may be damaged. Recent versions have a through hole with a cap screw and nut arrangement. For this version, the cap screw and nut should be tightened according to the torque chart for steel in the appendix. Exhaust Valve Assembly When installing a new exhaust valve, lubricate the head of the valve stud and push the exhaust valve on over the head of the valve stud. Reattach the exhaust nozzle to the upper housing. Snug the screws using the aluminum torque chart in the appendix, but do not overtighten, as the threads in the aluminum housing may be damaged. 15

PIONEER PUMP VACUUM ASSIST SYSTEM (CONT.) Alignment The vacuum pump is mounted two different ways on Pioneer Pumps: on top of the pump, and for large model pumps, on the side of the pump. In each case, it is important to ensure that the drive belt is aligned between the pulley on the centrifugal pump drive shaft and the pulley on the vacuum pump itself. This adjustment is done by positioning the drive pulley on the ce

PIONEER PUMP VACUUM ASSIST SYSTEM (CONT.) Theory of Operation The vacuum pump is a key part of the priming system . Its function is to remove air and create a vacuum at the pump suction port while the centrifugal pump input shaft is rotating . From the diagram, the key functional parts of the vacuum pump are: 1 . Pump casing 2 . Inlet valve 3 .